Catalytic process and apparatus



April 10, 1945. J. DquPHAM ErAp. 2,373,358

CATALYTFC PROCESS AND APPARATUS Filed qu. 31, 194; 2 sheets-sheet 1 RETENTlv-E- f MATERIAL 5 fax-:GENERATION EFFLUENTS cATALYs-r POWDER EGENERATloN GAS REACTOR E FF LUE NTS INVENTORS J. D .UPHAM BY I. L .WOLK

Filed Dec. 31, 1945 -2 Sheets-Sheet 2 REACTOR INCOMING REGENERATION PREHEATED EFFI UENTs FEED EFFLUENTs FEED UNIT 3o l y, l/

PREI-IEATED REACTOR INCOMING REGENERATION FEED EFFLUENTs FEED I-:FFLUENTs UNIT 32 REGENERATION FSREHEATED REACTOR INCOMING EFFLUENTs FEI-:Dl` EFFLUENTs FEEDl UNIT234 1 INCOMING REGENERATION/ PREI-IEATED REACTOR FEED EFFEUENTs FEED EFFLUENTs UNIT 36 TIME f /'/G`.` A I REACTOR RE'GE NERATION PREHEATED INCOMING EFFLUENTS EFFLUENTS FEEDy FEED UNIT 3o INCOMING RE'ACTOR REGENERATION PREI-IEATED FEED EFFLUENTs EFF-I UENTs' FEED UNIT 32.

PREI-IEATED I INCOMING REACTOR REGENERATION FEED FEED EFFI UENTs 'EFFLUENTs I UNIT 34 REGENERATION FREI-IEATED INCOMING' REACTOR EFFLUENT-s FEED -FEED EFFLUENTs UNIT 36 T'ME F/G -3 Z FURGE lNvENToRs `I.D.UI=HAM .BY I. I .wOI I` April 10, 1945-. J. D. UPHAM Em 2,373,358

CATALYTIC PROCESS AND APPARATUS AT'r RNE U62 resented Apr. 1o, 1945 UNITED STATES:

YPATENT OFFHCE y Y 2,313,358 s cArALr'rIo mocsss AND APPARATUS John n. Upnem and 1. Louis welk,` Bartlesville, Okla., assignors to Phillips Petroleum Company, a corporation of Delaware l 'Application December 3l, i943, Serial` No. 516,438

10 Claims. (Cl. ills-52) using a powdered catalyst suspended -in hydroa carbon vapors. In preferred embodiment it relates to heat utilization in such conversions, and" to separation of finely divided catalyst from fluids. The invention is applied with particular advantage to endothermic conversions in which the w catalyst is regenerated by the exothermic combustion of carbonaceous matter deposited thereon during conversion.

Many processes for the conversion of hydrocarbon materials to other hydrocarbon and/or la non-hydrocarbon materials are now carried out with the aid of catalysts. In fact, catalytic processes, due to their greater selectivity and other advantages, are nowl displacing almost all types of non-catalytic operations in the petroleum industry. Merely as examples of such conversions may be mentioned the cracking of oils to products of lower boiling point, the formation of products of higher boiling point than the reactants as by polymerization or amlation, the isomerization hydrogenation, dehydrogenation, reforming, desulfurization, aromatization, partial oxidation, halogenation, etc., of hydrocarbon materials,lv which may -be essentially pure individual hydroess of the present invention is applicable toiallf such processes, as well as to other catalyzed chemical reactions generally. Inasmuch as the catalytic cracking of oils is an important, and in some respects typical, example of hydrocarbon 35 conversion processes, the invention will be described in detail as applied to such a cracking process byway of example. In the catalytic cracking of hydrocarbons,

which is an endothermic reaction, a solid`catalyst Il is ordinarily used, which may be disposed in a stationary bed', oriwhich may flow through the system either as a moving 'bed of moderate-sized particles or as a nely divided powder which may be partly or entirely suspended in the reactant or 5,

regeneration gases. For example, in the socal1ed uid catalyst system, the solid catalytic material is utilized in the form of a fine powder of say 200 to 300 mesh on downto a few microns in particle size. This powder ls preferably "aci-ated lo with gaseous hydrocarbon reactants, purge gases, or regeneration gases .to `such an extent that it is maintained in a freely-flowing or'fiuent condition. The catalyst is thus handled much as a liquid would be. and passed continuously 'in a Il to suitable equipment for separation into the deolosed circuit comprising a reaction chamber and regeneration chamber, as well as purging zones, stand-pipes, conduits and the like. Gaseous effluents from reaction and from regeneration zones are passed through cyclone separators or their equivalent to remove suspended catalyst therefrom, which may be returned to the zone whence it carne or passed to the other zone. vIn such processes it is dilcult to remove the last traces of the powder from the gas streams referred to. Normally the major portion, such as from,90 to 99 per cent, of the powder is separated out in one or a series of cyclone separators.- The lresidual powder carried out in gaseous eilluents of such separators has been a source of considerable trouble. It is either lost entirely yfrom the system, or is recovered by other means which are expensive or which have inherent disadvantages. A small catalyst withdrawal from the system is required, accompanied by introduction of new catalyst make-up, for the purpose of maintaining the average activity of the catalyst, but the amount of residual catalyst escaping from the cyclone separators is greatlyin excess of the required withdrawal. One method of recovering residual catalyst from reactor emuents is to pass Athe latter to a partial condensation or fractionation zone, wherein the catalyst ypowder may be 1 separated in heavy liquid hydrocarbons concarbons or mixtures of hydrocarbons. 'Ihe proc, 30

densed therein. When such liquid is recycled to the reactor, the catalyst is also returned, but without being regenerated. Furthermore, this does notrallow removal of heavy endsv from the system without carrying residual catalyst out .y

therewith.y For recovering residual powder from spent regeneration gases electrical precipitation is generally used, which of course is'expensive with respect both to initial and operating costs.

However, if such methods are not used, an almost i prohibitively expensive catalyst loss is incurred.

ity fiowtherethrough is removed from the bottom by means of a. rotary valve or equivalent mechanisrn.` The hydrocarbon material to be converted is usually passed in the vapor phase upwardly4 through the rreactor counter-current to the catalyst flow. Reaction eflluents are passed siredr products, recycle stocks, and other components. Spent catalyst taken from the bottom of the reactor is purged of residual hydrocarbons and passed to the top of a regeneration zone which may be similar to the reaction 'zone in construction and operation. The 'catalyst passes down through the regenerator counter-current to a stream of air or other oxygen-containing gas which removes the carbon byr combustion. Catalyst thus regenerated 'is purged of residual oxygen-containing material and passed `by bucket elevators or other means to the top of the reactor for reuse.

marked extent, the magnitude of which depends on the properties of the particular catalyst used, as well as on reaction and regeneration conditions and on equipment design. Eifiuent conversiongases and/or regeneration gases sometimes carry such fines in suspension, thus presenting problems somewhat similar to, though usually less marked than, the problems mentioned above with respect to the fluid catalyst processes.

The various hydrocarbon and other conversions which areeiected in the presence of solid catalysts are mostly carried out at elevated temperatures. Thus, substantial heat is required to raise the feed to reaction temperature. Furthermore, in the case of endothermicA reactions such as cracking, the eiiiciency of conversion is effected by a temperature drop which would normally occur during reaction, and sufficient heat must be supplied to the reaction zone direct or to the feed to supply the endothermic heat of reaction. The heat contained in the hot eiiluents from the reaction zone is usually at least partly wasted during the cooling and fractionation required in order to eiect separation of desired products. In the regeneration step, a substantial amount of heat is liberated by the exothermic combustion of carbonaceous matter on the catalyst, and various methods have been proposed for using a portion of the heat so liberated to supply heat for the endothermic conversion step or for other purposes. However a substantial amount or all of this heat is frequently wasted.

Itis an object of our invention to effect chemical reactions with the aid of mobile catalysts.

It is another object to provide improved hydrocarbon conversion processes. l

A further object is to supply heat to an endothermic conversion.

Another object is to recover a substantial amount of the sensible heat contained in gaseous conversion and/ or regeneration effluents in processes of the nature described, and to utilize sorecovered heat in the process.

In systems of this type, attrition of the catalyst particles to form fines occurs to a eration zone and heat contained in eiiluent from the conversion zone are utilized in a novel and efficient manner to supply at least a. portion of the heat required to preheat feed to the con, version zone.

Adidtional objects and advantages of the invention will be apparent, toone skilled in the art, from the accompanying disclosure and description.

Briey stated, the present invention in preferred embodiment comprises subjecting hydrocarbons or other reactants to the action of a mobile solid catalyst, whereby fluid eiiluents from the reaction zone carry powdered catalytic material in suspension therein. Catalyst is subjected in a separatefzone to contact with an oxygen-containing gas to burn-oil carbonaceous deposits from the catalyst and regenerate same, whereby fluid eiiiuents from the regeneration zone also may carry powdered catalytic material in suspension therein. Such eilluents from one or both zones are then passed to one or more heat and catalyst recovery zones wherein they are passed through a bed of particulate or granular heat-retentive material which has a particle size substantially greater than the powder, such that the fluids may pass therethrough without excessive resistance to flow. In this manner a substantial part of the sensible heat of the fluids is absorbed by the bed of heat retentive material while at the same time the powdered catalytic material carried out of the reaction and/or regeneration zone is separated from the iuids by deposition in said bed, which acts as a ilter. The conversion and/or regeneration eilluents are thus obtained free from suspended powder and at an appreciably lowered temperature. After the bed has become laden with powder and/or approaches the temperature of the fluid passing there- 40 through, a relatively cool fluid which it is de- A still further object is to improve catalytic sired to pass into the system, preferably feed to be converted, is passed through the bed in an opposite direction, whereby heat and powder are both picked up from the 'bed and returned to the system.

In a preferred manner of carrying out the present invention, heat contained in the efiluents from either or both the reaction and regeneration zones is conserved for preheating feed to the conversion zone. By contacting hot eiliuents from the conversion or regeneration zones, or both, with refractory heat, absorbent material arranged as filter beds, a substantial proportion of the sensible heat contained in these streams may be absorbed and retained very efficiently by Adirect heat exchange. Substantially all the powdered catalyst is also readily retained. On contacting hydrocarbon feed with the thus-heated refractory material, said feed may be preheated to a desired point by 'direct heat exchange, and by properly correlating the nature and volume of refractory material to the ow rate and contact time of the respective streams, and by alternating a plurality of heat;v absorbing zones between heat (and catalyst) absorbing and heat (and catalyst) liberating cycles important economies of heat, may be provided while permitting efcent operation of the catalytic process. In customary practice, the emuent from the conversion heat are concomitantlyreturned t0 the reaction zone is at or near reaction temperatures and must be cooled prior 'to or during treatment for recovery of desired products.` Thus it can be seen that in so doing the sensible heatcontained in this stream is wasted.. In accordance with present practice, carbon-deactivated catalysts are re- The resultant products .o'f ombustion are at ele@l vated temperatures since 'the reaction 'isex,

othermic, and containa great amountof sensible'eV heat which it is desired 4to utilize in 'an emcient f manner. In accordance with the present inventionmeans are provided for separately absorbing heat from either the reaction eiuent or the regeneration eiiiuent, or both, on one cycle, giving up this heat to hydrocarbon feed on another cycle, while absorbing heat from eiiluents of this cycle in other heat absorbing means, the cycles being alternated in a manner which will enable the operation to be carried out continuously.

In referringto heat absorptive or retentive material, or regractory material, we mean a solid material having desirable thermal properties, particularly a relatively high heat conductivity. Such a material in the practice of this invention is used in a particle size, or range of particle sizes, which will provide a satisfactory lter bed for the particularuids undergoing treatment.

`Specific aspects of particle size and iiltering y characteristics will be discussed in more detail below. With respect totheparticular material to be used, desirable thermal qualities in such a material involve a high specific heat, high density, and highheat cgnductivity. It will be yappreciated that the term'highris a relative one, and that accordingly a wide range of\ mate- The material must of course have a melting point y appreciably vabove the maximum temperature which is likely to be encountered, and must also beable to withstand such maximum temperatures without undergoing other undesirable changes. Ordinarily the-heat retentive material is substantially inert under the conditions of use with respect to the iiuids to be contacted and to the apparatus, and ls preferably of a non-adsorptive nature. With these general limitations in mind, a listing may be made of some examples of materials lsuitable under .various conditions for use in carryingout the invention. .This listing is, of course, not intended to be all inclusive, and other suitable materials will be suggested to one skilled in the art by the disclosures offered herein.

The metals may be cited as one class of materials. With respect to thermal properties, the

i metals are more desirable than any other class of solids. However, certain of the metals are highly reactive, and hence may not be suitable for use in the presence of oxidizing or' other active gases, such as those containing free halogens, acids, etc. Furthermore, the melting points of'the metals are of course to betaken into considerationin making a choice for a specic application. The metals and in fact all solids,

Fahrenheit, and few solids of any kind have speciiie heats much above about 0.4 under .similar conditions. The densities oi' most metals are vary between one another inv heat conductivity roughly in the range of about 400,.-pounds per .Y

cubic foot, although-theplighter metals. maybe lessfthan 200fpo'unds per cubic'foot, and mostnon-metallic refractory solids which may be used in the present process have densities between about 100 and 200 pounds per cubic foot. In

contrast, the heat conductivities of' suitable metals may vary from about 200 B. t. u./hr./sq. ft./F./inch in one case up to over 2000 in an other case, and non-metallic solids which may be given consideration for use in carrying out our invention may have heat conductivities as low as 1. It is accordingly apparent that most of the solids will be similar with respect to density and specific heat, while they may be quite dissimilar with respect to heat conductivity. With due consideration being given to cost and other such factors, a solid having a high heat conductivity would ordinarily be selected for actual use, and specic heat and/or density would play a part in the iinal selection only in deciding between two or more solids of similar high heat conductivity.- v

Returning now to the metals, the following may be mentioned' merely as examples having relatively high melting point, and are listed approximately in decreasingorder of heat conductivity, that is from the highest to the lowest: copper, aluminum, brass, nickle, iron, mild steel, chromium alloys, etc. The thermal conductivity of the highest in` this list, copper, is more than ten times that oi the lowest in the list, chromium alloys, the former having a conductivity at 1000" F. of about 2400 Bt. u./hr./sq. it./F./in., and the latter having a conductivity of about 200. Ili'he above list of course is not exhaustive but merely suggestive, to one skilled in the art, of

the wide variety of materials available and their 0 bility. After some metals are thus eliminated,

consideration is given to the availability and cost of the remaining suitable metals in desired particle size, then the heat conductivity and iinally, if more than one metal still appears suitable, the

density and specic heat are taken among th determining factors.

Considering now the non-metallic solids, it is,

immediately apparent that a lower order of heat conductivity is involved. However, due to fac tors such as cost, chemical inertness, resistance `to attrition, and particularly to refractory qualities'at high temperatures, a non-metallic solid is frequently more desirable than a metal. Arti- `ficial graphite 'and silicon carbide ('Carborun dum') are outstanding in that their heat conductivities are far above those of any other nonseldom suitableA for use in our invention. Thel heat conductivity of silicon carbide varies considerably with temperature, but generally speaking is within the range of about 100 (in the units used above), varying from to 2500 F. to 125 at 11007F. The reasons for our preference for silicon carbide thus become apparent when its thermal, mechanical, and chemical characteristics are considered. Y

Other non-metallic solids available for use in various modiiications of the invention include the following examples listed in approximate decreasing order of heat conductivity (at elevated temperatures of 1500 to 2000 FJ, which ranges from about 25 on down to about 1 to 2: fused alumina, magnesite, quartz, other `forms of dense silica, firey clay, porcelain, rocks of various kinds, diatomaceous earth (fired) etc.

As stated above, the particle size, heat conductivity," and heat capacity of the solid material are correlated to give the desired rate of heat transfer. Hence the amount of heat absorbent used in a filter bed in carrying out the present invention will be greatly dependent on the flow rates, temperature and specic heats of 'gases treated, but the proper amount may readily be caluculated by one skilled in the art for any given conversion process, once the process variables areknown. Inasmuch as the powdered catalystcarried in the eiliuent streams will always be of quite small particle size, although this will vary with gas velocities, size of the bulk of the catalyst used, and efficiency of any preliminary catalyst separating means used, some fairly specific data may be given on suitable particle size of solid `heat absorbent used in making up the filter beds,

and arrangement of such beds.

It is generally advantageous to provide a bed of substantial cross-section across the line of ilow of gases. 'I'his ensures a relatively low velocity of iiow through the bed which aids greatly both the iiltering and the heat absorbing functions of the bed. It is further advantageous, although not essential, to employa bed made up of graduated particle size, preferably one in which the top and bottom of the bed (if it is horizontal) are composed of relatively large particles, such as those having a diameter of about one-half to onequarter of an inch, while the middle portion of the bed is composed of smaller particles, such as from 4 to 6 mesh down to say 2O mesh, but in any case not smaller than 100 mesh. This particular arrangementl is' very stable toward even relatively high rates of gas flow therethrough. While a. clogging or packing of the bed with powdered catalyst is avoided, the complete removal ofsuch powder from the etiluents being treated is also assured. After a few runs, reverse flow of gas readily picks up substantially all the powdered catalyst deposited on the bed. Particle sizes in the range described also allow a very rapid transfer of heat by direct heat exchange with the gases.

Turning now to the drawings and description thereof .for more specific application of the invention, Figure 1 shows in somewhat diagrammatic form a preferred arrangement of equipment, partly in elevation and partly cut away, together with ow of materials therethrough, which will serve to illustrate and also exemplify apreferred embodiment of the invention as applied to the fluid catalytic cracking of hydrocarbons. Figures 2 and 3 show schematically the time intervals during which various units are utilized for the diierent portions of two different'fourstage cycles. It will be appreciated that the representations are merely schematic, that no attempt has been made to proportion the various units exactly to scale, and that inorder to simplify the drawings numerous auxiliary items, such as fractionators, pumps, compressors, heaters, condensers, heat exchanges, valves, control instruments and the like, have been omitted, as their use is :fell understood by one skilled in the art once given the detailed disclosure. provided herein. Accordingly the drawingsand examples are not to be construed as unduly limiting the scope of the invention.

In Figure l, chambers I and l2 are utilized y respectively for reaction and regeneration- Powdered catalyst flows continuously through these two chambers by means of conduits I4 and i6 as shown. Lines l5 and l1 are provided for purging catalyst between zones. The catalyst may be any solid catalyst suitable for use in eecting a given conversion. In the case of gas oil cracking, by which the invention is being illustrated, a synthetic gel-type silica-alumina composite is frequently used. In some cases a less active, but cheaper, natural clay-like materialsuch as an acid-treated montmorillonite clay of the nature of that sold under the trade name of Super-Filtrol, will be preferred. A bed of the catalyst is maintained in each chamber, the level of the catalyst being indicated by dotted lines, and this level is readily adjusted to any desired height. The particle size of the catalystl is correlated With vapor velocities realized within the chambers so that thebulk of the catalyst remains in the gasied or aerated bed by virtue of being slightly heavier than that which could remain entirely suspended in reaction or regenenation gases. A frequently used particle size is from 200 to 400 mesh, but other sizes may be used under various conditions. All these factors are well known in the art and need not be further considered here.

Reactants enter line i6 from line I8 and carry the catalyst into chamber Ill by gas-lift action. The so-introduced reactants pass upward throughV the catalyst on into the vapor space above, then via line I9 into cyclone separator 2!) wherein part of the catalyst remaining suspended in the vapors is separated and falls back down into the chamber through Iconduit 25. Vapors next may pass via line 2! int@ cyclone separator 23 for further separation .of residual catalyst which is returned via line 2l. It will be understood that one, two, or more separators of this type may be used as desired. However, the complete separation of catalyst in this manner is not feasible, as has been discussed before. Reactor eliluents exit via line 22 and pass to further steps as will be described later.

In a similar manner, regenerating gas such vas air, passes from line 24 into conduit lli, lifts the spent catalyst .therein into chamber l2, effects combustion of carbon on the catalyst therein, and exits'via. lines 29 and 3l and cyclone separators 26 and 3 1, nally exiting through line 28 still carrying residual catalyst. From line 28 regeneration eilluents are passed tofurther treatment in accordance with the invention, as will be described below. Catalyst from the two cyclones vreturns to chamber l2 by way of conduits 33 and 35.

While the above description has been directed to one advantageous method of carrying out the cracking and regeneration, other conventional ent invention; it will be seen that four chambers,

Il. I2, 34, and 36, are shown with the outer wall partially or completely cut away. Each of said chambers contains a bed of granular heat retentive material such as carborundum, crushed iirebrick, metal, etc., chosen in accordance with the principles hereinbefore set forth. Carborundum is preferred due to its high heat conducting properties.

The heat retentive material is arranged in such manner as toallow ilow of gases therethrough with minimum pressure drop consistent with an effective iiltration effect. The bed thus acts not only to absorb or liberate heat, but also eiectively removes the powdered catalyst from gases eilluent from chambers I or I2. By reverse flow of gases, the thus-separated catalyst is readily picked up and returned to the conversion or regeneration zones as desired, as will appear more fully as the description` proceeds. In order to illustrate more than one method of arranging the heat retentive material, a slightly different arrangement isshown in each chamber. lOrdinarily, the same arrangement, chosen as optimum for a given set of conditions, will be used in each chamber,

In chamber 3D is shown a bed in which the particle size is graduated from large to small from the top to the middle and the reverse from the middle to thev bottom. Powdered catalyst is shown deposited on top of this bed. In chamber 32 is shown a bed, supported on a relatively fine screen, which the particle size is graduated from large to small in only one direction, that is top to bottom. In chamber 84 is shown a bed in which strata of diierent particle size are sepa- While in some cases, particularly where diilerent particle sizes are used in a bed, it is preferred to maintain the bed in the same arrangement without disturbance, in other cases, particularly when very'little if any smaller particle sizes are used, it is preferred to subject the bed to Yan occasional or frequent shaking or rabbling action to dislodge any catalyst which may have become caked and is thus clogging passageways.

Provision of an empty space above and below the bed allows a drop in velocity of entering gases and also a more even flow thereof through the bed.

-Lines 38, 40, 43,' and 68 are connected with the four heat-retainer units shown (it is understood that the number may be less or greater than four in any given instance)` so that hot gases, carrying suspended catalyst, from either line 22 or line 28 may be passed downwardly through any of the units. Certain of the connecting lines and valves are 'shown in the drawings without being numbered, since their use will be obvious to one skilled in the art in. view of the detailed description of iiows offered herein; to designate and describeeach and every line and valve by a numeral would only serve to 4encumber the drawings and burden Ithe description without contrib-1 uting materially to an understanding of the prin ciples of the invention or the specific methods of operating described. Gases, either conversion effluents cr regeneration eiliuents, pass from thel units, after downward iiow therethrough, to product separation or other vsteps (not shown) via lines 46, 48, 50 and 62. The treatment of such eiiiuents is Well understood in the art, and need not be considered in further detail. Sufiice it to say that unconverted gas oil is usually separated and recycled for further treatment, while gases,

stocks, are recovered for desired use.' Regeneration eiiiuents may ybe in part recycled, passed to waste heat boilers for recoveryof sensible heat f not retained in the heat-retaining zones, discarded, or given other handling as conditions v spectively. These lines are connected to line 62,

carrying a purge gas such as steam or an oxygenfree ilue gas, and, to line 64@` carrying relatively cool incoming reactants such as gas oil. Reactants pass from any one of the heatn retaining units via lines 16|, 18, 80, or 82'into line 66, and thence to line I8 for introduction into the reactor I0. Additional reactants may be introduced into line I8 through line 16, as and if required. A heater 14 is interposed in line I8 for heating reactants additionally, if required. Any purge gas introduced into the heat-retainer units to purge hydrocarbons therefrom is ordinarily passed on into line 66 and thence to thev reactor where it acts merely as a diluent, and also insures recovery of hydrocarbons and any catalyst picked. up from the zones. However, it may be discarded or passed to other points in the system through lines 84, 86, 88, or 90 if desired. Purge gas introduced from conduit 62 to purge out regeneration effluents is usually taken out of the units through the last-named lines. It will generally be preferable, however, to introduce this^purge through lines 84, 86, 88, and 90, and exhaust the same through lines 46, 48, 50 and 52; down-flow in this manner avoids picking up any deposited catalyst from the top of the filter-heat retainer bed.

In the event a two-stage preheating of feed is desired, which will be described in detail below,

line 92 branches oir from line 64 and is connected to lines'38, 40, 42, and 44 to carry incoming reactants to the top, rather than the bottom, of the units. Reactants which are thus introduced are preheated without picking up catalyst, and then may be passed to the bottom of any other unit, by means of line 84 and'its connections,- for Afurther preheatihg and for picking up catalyst prior to their final passage through line 66 and into the reactor.

In one mode of operation, in which heat-retaining unit 36 is not used, incoming reactants, either liquid or vapor, from line 64 pass upwardly through unit 30, thereby being heated by absorp ing sensible heat from the reaction products,

4 passing therefrom via line 42 into the top of heatretaining unit 34, wherein residual catalyst is' separated gtand heat is absorbed. The cooled, catalyst-free gas exits through line 50.

Aftery a relatively short period of operation,

perature close or equalto that of the reactorl gasoline, naphthas, and bottoms of varying na-- ture, depending on reaction conditions and feed perature close or equal to that of the spent regeneration gases. The iiow of gases through these units is then switched so that incoming reactants pass through unit 34 which is now at.the highest temperature, reactor effluents pass through unit 30 which is at the lowest temperature, and regen eration-eiiiuents pass through unit 32 to impart additional heat and temperature thereto. In this way the cycle is continued indefinitely. Thus one heat retainer-niter unit goes continuously through the following cycle:

1. Reactor eliluentsdown. 2. Regeneration edluents down. 3. Reactants up.

Asan example, typical temperatures of the streams in a catalytic cracking of gas oil are:

. F. Reactor eflluents 900 Regeneration eilluents 1,150 Incoming reactants Below 900 The actual temperature of the' incoming reactants determines the amount of additional preheat if any, imparted thereto either before contact with the hot lter bed or by heater 'I4 after such contact. It is generally preferred to contact the relatively cool feed with the filter bed to absorb the maximum amount of heat therefrom, and to bring the thus-preheatedfeed to final reaction temperature by means of heater 1I. However, the reverse procedure is also suitable. In any event, a temperature rise in the feed of from 100 to 400 F. more or less is obtainable by passage of feed over the hot filter bed. No attempt is made here to set out the limits of reaction conditions under which gas oil cracking or any other conversion and/or regeneration may be carried out in reactor l and/or regenerator I2, for this is well'4 within the knowledge of the art. and is notan essential of the invention.

An additional, and preferred, mode of operation utilizes four heat- -and catalyst-retaining zones. This cycle, from the viewpoint of one unit, comprises the following four stages:

1. Reactor eilluents down.

2. Incoming feed down.

3. Regeneration effluents down. 4. Feed (preheated-in step 2) up.

Lines 92 and 94 are used for carrying feed in this modification. In such a cycle, step 1 imparts heat to the bed and also deposits catalyst, step 2 recovers heat, but not catalyst, step 3 imparts heat v(at a higher temperature than step 1) and also deposits additional catalyst, and step 4 recovers additional heat, thus bringing the partially heated "feed to a temperature equal to or nearreaction temperature, and also picks up catalyst deposited from both the reactor and regeneration eliluents and carries same back into the reactor for reuse. 'I'hsfcycle is usually somewhat more advantageous -than the three-stage cycle previously described eiiiuents, and unit 3l becomes heated to a temlength of the bar represents the time required for a complete cycle, and within the bar is described the flow of material taking place during a given interval of time. By reference to this figure, one may readily determine the course a given stream will take duringan entire cycle, and also the flow through each filter-heat transfer. unit at anyv quired in some cases to prevent combustion or explosion in the units by mixing of hydrocarbons with oxygen-containing gases. In other cases it may not be necessary, The determination is well within the 'skill of the art. In the embodiment illustrated by Figure 2, a short purge with steam is used before and after passage of regeneration eilluents through a unit. 'Ihe simplest method of accomplishing this with only four units while still maintaining continuity of ow is merely to vent regeneration effluents during the short period re- I quired for purging. While this permits some loss of heat and catalyst, a small catalyst withdrawal from the system is necessary any way, and may be thus provided for. If it is preferred to prevent 40 generation eilluents is in a downward direction To provide a more readily visualized description of a cycle of the nature just described, Figure 2is presented. In Figure 2, each horizontal bar represents one' unit `as designated. The total t0 avoid picking up catalyst. The purge following passage of hydrocarbons, however, may be either down or up, and the purge gas is preferably introduced into the reactor. By using an i up-i'lcw purge, the steam or other purging gases may be used to pick up a substantial part of the catalyst and/orl heat and return the same to the system. l

Another advantageous 4stage cycle is illustrated in Figure 3, following the same conventions used in Figure 2. This cycle differs from that of Figure 2 in that a given unit, after having contacted reactor effluents, is next contacted with regeneration eiiluents. After this the preheated feed is passed upwardly forl picking upfflnal preheat and catalyst and then the partially cooled bed is contacted with cold feed. It will be readily seen that one cycle may be more advantageous than another in one instance, while. the reverse will be true in another instance. 'I'he factors X influencing the choice of a cycle include primar` ily the temperature of feed available and the temperature differential between reaction and regeneration zones.

It will be seen that various other cycles may be used as is most convenient for a given process, in which the temperatures and flow-rates of the various streams, extent of catalyst deactivation,

etc., must be taken into consideration. It is required that a fluid carrying powder first be passed through a. heat-retentive unit in onevdirection, and a fluid be then passed through the same unit in an opposite direction, picking up the powder previously deposited therein and carsaid catalyst in said bed and to absorb heat from said gases; passing cold gas oil feed through a third filter bed composed of solid heat retentive particles, previously heated by contact with hot reaction zone effluents passed in the same d irection therethrough, to preheatsaid gas oil feed by recovery of heat from said particles; passing vthus-preheated gas oil feed through a fourth the stream leaving., the bed will be subject to `v variation as the temperature of the heat retaining material approaches the temperature of the incoming stream. Such variations in temperature may be suiiiciently minor as not to disturb unduly the functioning of subsequent operations in the stream, or may be partially or completely compensated for by auxiliary variableheating (or cooling) means.

Although the heat retainer-filter units shown in the drawing are depicted as horizontal beds, they may of course be vertical, with horizontal flow therethrough, or inclined or other suitable positions. While the powder is shown deposited on top of the bed, the directions of fiow may of course be opposite, with the powder being deposited on and picked up from the bottom of the bed as desired. Furthermore, the units may be of variable cross-section of different levels in the bed; for example conical beds may be used.

The foregoing procedure may be applied to any hydrocarbon conversion reaction conducted at elevated temperatures and which requires preheating of feed, and in which catalyst is deactivated by deposition of carbon thereon. Such reactions, besides cracking, include dehydrogenafilter bed composed of solid heat retentive pai'- ticles, previously heated bycontact with hot regeneration zone eiiluents and having powdered catalyst therein filtered 'out of reaction zone effluents and regeneration zone effluents passed in -the opposite direction therethrough, to further heat said preheated feed nd to pick up said catalyst from said filter bed; and passing into said reaction zone so-heated gas oil feed carrying said catalyst thereby returning heat and catalyst to said zone.

-2. The methodof claim 1, in which said secondA filter bed is purged with an inert gasV before and after passage of said regeneration zone effluents therethrough.

3. A method of cracking gas oil which comprises continuously 'owing la powdered soliciv tion, aromatization, desulfurization, reforming/ fpolymerization, etc. The invention has been described primarily with reference to conversion processes effected at temperatures `lower than regeneration temperatures, which is the more usual c ase. In instances wherein conversion temperatures are above regeneration temperatures, suitable modifications may be made readily by one skilled in the art so that the feed being preheated will always come into contact with the hottest body of heat retentive material last. These and many other `modifications will be obvious to one skilled in the art in'view of the disclosure herein.

We claim:

l. A method -of cracking gas oil which coniprises continuously flowing a powdered solid cracking catalyst through a closed circuit comprising a reaction zone and a regeneration zone;

4'0 gases; recovering hot gases effluent from said repassing gas oil vapors at cracking conditions of previously cooledby contact with preheated gas oil feed, to,deposit said catalyst in said bed and to absorb heat from said gases; recovering hot I gases eiiiuent from said regeneration zone containing residual powdered catalyst at a temperature higherthan said gases eiiiuent from'said reaction zone; passing same through a second/filter bed composed of solid heat retentive particles, previously cooled by contact with vcold gas oil feed whereby said feed was' preheated, to deposit prising a reaction zone and a regeneration zone;

passing gas oil vapors at cracking conditions ofy temperature and pressure through said reaction zone; passing an oxygen-containing gas through said regeneration zone under conditions to burn carbonaceous matter from said catalyst andreactivate same; recovering hot gases eiliuent from said reaction zone and containing residual powdered catalyst; passing same through a first filter bed composed of solid heat retentive particles, previously cooled by contact with cold gas oil feed whereby said feed was preheated, to deposit said catalyst in said bed and to absorb heat from said generation zone containing residual powdered catalyst at a temperature higher than said'gases eiiiuent from said reaction zone; passing same cold gasoil feed by recovery of heat from said further heat said preheated feed and to pick .up

said catalyst from said filter bed; and passing into said reaction zone so-heated, gas oil feed carrying said catalyst, thereby returning heat and catalyst to said zone.

4.1The method of claim 3, in which said second filter bed is` purged with an inert gasbefore and" after passage of said regeneration zone effluents therethrough.

5. In a process for the catalytic conversion of.

hydrocarbons in which a mobile solid catalyst is .deactivated by deposition of carbon thereon in a reaction zone and reactivated by contact with oxygen-containing gas in a regeneration zone, and in which gaseous eiiluents from said zones contain catalyst fines, the steps which comprise contacting effluents from said reaction zone at substantially reaction temperature with a first body of heat retaining particles arranged as a hotter of said bodies, said latter contacting being enacted under conditions adapted to suspend in said feed nes primarily'retained in said body by filtering action.

6. In a process for the catalytic conversion of hydrocarbons in which a mobile solid catalyst is deactivated by deposition of carbon thereon in a lreaction zone and reactivated by contact with oxygen-containing gas in a regeneration zone, and in which gaseous emuents. from at least one.of said zones contain catalyst iines, the improvement which comprises passing eilluents from the cooler of said zones downwardly through a filter bed composed of heat absorptive particles, then passing ellluents from the hotter of said zones s downwardly through said filter bed, whereby heat is absorbed from effluents of both said zones and said fines are deposited on and in the upper portions of said bed, then passing hydrocarbons to be converted upwardly through said bed to pick up said heat and said ilnes" and thence into said reaction zone.

7. The process of claim 6, wherein saidvheat absorptive particles comprise silicon carbide.

8. Apparatus for catalytic conversion of hydrocarbons whichcomprises a reaction chamber' and a regeneration chamber, means for flowing powdered solid catalyst through a circuit comprising said chambers, a pair of filter beds composedof heat retentive particles, means for flowing hydrocarbon reactants through said reaction chamber, means for separating the hull: but not all the powdered catalyst from reaction chamber effluents, means for passing said reaction chamber eiliuents through one of said pair of filter beds, means for flowing oxygen-containing gas through said regeneration chamber, means for separating the bulk but not all of the powdered catalyst from regeneration chamber eilluents, means forpassing said regeneration chamber efliuents through the other of said pair of lter beds, means for passing hydrocarbon reactants through said pair of lter beds, 'said `passage through the last of said pair of lter beds being in a direction opposite to the 'flow of eiiiuents therethrough, and means for passing reactants from the last of said pair of filter beds into said reaction chamber. r

9. Av method for catalytic conversion of hydrocarbons which comprises owing a finely divided conversion catalyst through a reaction zone and a regeneration zone; passing hydrocarbons under conversion conditions of temperature and pressure through said reaction zone; passing an oxygencontaining gas through said regeneration zone containing catalyst deactivated by deposition of carbonaceous material thereon in a previous conversion under conditions to burn carbonaceous material therefrom and vreactivate same; recovering hot gases efuent from said reaction zone and containing residual powdered catalyst; passing same through a first filter bed composed of solid heat retentive particles, previously cooled by contact with preheated hydrocarbon feed, to depositsaid catalyst in said bed and to absorb heat from said gases; recovering hot gases emuent from said regeneration zone containing residual powdered catalyst at a temperature higher than said gases eilluent from said reaction zone; passing same through a second filter bed composed o f solid heat retentive particles, previously cooled by contact with cold feed whereby said feed was preheated, to deposit said catalyst in said bed and to absorb heat from said gases; passing cold feed'through a third filter bed composed of solid hea-t retentive particles, previously heated by contact with hot reaction zone eiiiuents passed in the same direction therethrough, to preheat said feed by recovery of heat from said particles; passing thus-preheated feed through a fourth filter bed composed of solid heat retentive particles, previously heated by contact with hot regeneration zone eilluents and having powdered catalyst therein ltered out oi' reaction zone eiliuents and regeneration zone eilluents passed in the opposite direction therethrough, to further heat saidv preheated feed and to pick up said catalyst from said filter bed; and passing into said reaction zone soheated feed carrying said catalyst thereby returning heat and catalyst to said zone.

10. A method for the conversion of hydro- 'K carbons which comprises continuously flowing a powdered solid conversion catalyst through a closed circuit comprising a reaction zone and a regeneration zone; passing hydrocarbon vapors at conversion conditions of temperature and pressure through said reaction zone; passing an oxygen-containing gas through said regeneration zone under conditions to burn carbonaceous matter fromsaidnatalyst and -reactlvate same; recovering hot gases eiiiuent from said reaction zone and containing residual powdered catalyst; passing same through a first filter bed composed of solid heat retentive particles, previously cooled by contact with cold hydrocarbon feed whereby said feed was preheated, to deposit said catalyst in said bed and to absorb heat from said gases; recovering hot gases efiluent from said regener-l ation zone containing residual powdered catalyst at a temperature higher than said gases efliuent from said reaction zone; passing same through a second' lter bed composed of solid heat retentive particles, previously heated by contact with hot gases euent lfrom said reaction zone, to deposit said catalyst in said bed and to absorb further heat from said gases; passing cold feed through a third illterbed composed of solid heat retentive particles, previously contacted with preheated hydrocarbon feed, to preheat said cold hydrocarbon feed by recovery of heat from said particles; passingl thus-preheated hydrocarbon feed through a fourth filter bed composed of solid heat retentlve particles, previously heated by contact with hot regeneration zone eiiluents and having powdered catalyst therein filtered Y outyof reaction zone eiiiuents and regeneration zone effluents passed in the opposite direction therethrough to further heat said preheated feed and t0 Pick up said catalyst from said filter bed:

and passing into said reaction zone so-heated feed carrying said catalyst, thereby returning heat and catalyst to said zone.

JOHN D. UPHAM. I. LOUIS WOLK. 

